Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Lincoln Aviator owners, lightly cleaned up (personal details are redacted by NHTSA).
At 13,650 miles the engine destroyed itself due to a defective crankshaft. I was driving home at night in the rain when the engine light came on and a loud banging sound was coming from the engine compartment. I immediately pulled off the highway & called roadside assistance. I waited for 3 hours for a tow truck and eventually had to call ct state police who summoned a wrecker. The lower half of the engine was completely destroyed. Manufacturer replaced the engine with a new engine assembly and engineers requested the old engine be sent to them for inspection as they had never seen this defect before. I was without my vehicle for 15 days. The first night I picked it up the engine light came on after less than 20 miles on my way home, again at night. It was not a dummy light. Another defective part had to be replaced. This time it was the EGR module. …
Tl* the contact owns a 2004 Lincoln Aviator. The contact was driving approximately 30 MPH, approaching a complete stop. While the brakes were engaged the vehicle accelerated toward the oncoming traffic. The brakes were applied repeatedly allowing the vehicle to come to a complete stop. The contact was able to continue normal operation. The failure occurred on three different occasions. The vehicle was taken to an authorized dealer on three separate occasions for the identical failure and the technician was unable to duplicate the failure. Also, the vehicle was taken to an independent mechanic on two different occasions for the acceleration failure which there was no resolutions. In addition, there were intermittent failures with the engine misfiring and revving without warning. …
1 year after purchase at 52,000 -replaced coils (recalled) , brake switch, cost just to lead and find issues after full service maintenance, $1500. 2 yrs in, transmission due to thing that is attached and looks like a brain plate to the transmission, (sms pack)still owing plus now, upcoming on latest transmission/computer/ at 84,000 :( s car has taken me completely upside down and in the hole owing $12,000 + $3000 for newest repair. Just got car back and now it feels like there is a potential small delay and wants to jump in the middle of traffic which I just experienced yesterday. Why is this car still on the road and not recalled. The problems go on and on and on. I emailed Ford and was basically told to take the car into their dealership where I can be robbed even further. Sad!! These are only a small fraction of links that are out there due to Lincoln having known issues. …
This is the 3rd time that my 2004 Lincoln Aviator has shut down while driving it... With kids in the car. No steering, no breaks, and 60 MPH down the highway. This car is sure to be the death of me... I have been lucky 3 times now, but what about the next time??? Voluntary service recall... Manufacturing defect of the coil packs... Issued by epa.gov (found after digging), replacement of the coil packs are covered until 120,000 miles. Ford will only replace one at a time, not all of them, so each time one is replaced.. I still have the risk of another going bad. Had four replaced so far, another tomorrow. I cannot believe that Ford can get away with this knowing that they are putting people's lives in danger. A car completely shutting down while driving at 60mph because of a defect during the manufacturing process doesn't cause concern for a recall... …
2004 Lincoln Aviator 74,000 miles. While attempting to merge onto interstate 95 s the vehicle shuddered and lost power unable to accelerate. Final determination by a mechanic determined the #8 cylinder was not holding pressure because the valve was not sealing correctly. The 4.6l v8 Ford engine's valve's are powder coated and this caused the value to stick and overtime warped the valve's components due to excessive heat. This is an engine design defect and the engine and will require a complete valve job to replace the head, head gasket and faulty valve stem. Ford has issued a technical bulletin on the subject but will not perform a voluntary recall. This is a serious safety issue and could cause serious injury or death if the vehicle losses power while merging with or evading oncoming traffic.
My 2004 Lincoln Aviator engine has a burnt valve with less than 90K miles on it. Rich morton Lincoln dealership in glen burnie, md says my repair will be $5,400 if I want to fix it, which they do not recommend. I see online that many others have the very same problem with this vehicle. I have also had to tow in my car as several times the gearshift stuck in park and could not be shifted to drive. I spoke with other owners who had the same problem. Also, my tailgate window randomly flies up while driving, just like other owners have reported. My main issue is that my vehicle, an expensive one, is now not drivable and needs the $5,400 repair because of a defect in manufacture that Ford will not acknowledge. Help, please.
When I turn on my 2004 Lincoln Aviator to warm up in the morning the smell of the gas is so strong. When I am at a red light or stop sign the car shakes so much that I have to put it the car in neutral to avoid the car from turning off. When I am driving the car jerks and stalls I feel scared when driving on the freeway because my car sometimes doesn't go as fast as the other cars because it stalls. The car drives rough and makes a whining noise all the time. Everytime I turn on the ac it makes a loud popping sound. I have not had my vehicle fixed or looked at due to my financial circumstance. My vehicle does not have warranty. I fear for the safety of me, my family and the public when I drive this vehicle.
Check engine light came on 2 years ago or so. Took into shop. Replaced coil #8 and spark plugs. Several months later, light comes on again, this time #7. 2 days later, light comes on again, must have been a defective part, replaced the replaced #7. Another 2 days later, light back on. I'm told it's a cylinder head problem and they won't know what exactly the problem is until they take the cylinder heads off. Or I can get a new engine.... Lincoln wants no responsibility for such a catastrophic and known problem. Since my mileage is over their warranty (although at the onset it wasn't). Gee, I wonder why no one wants to buy an American made car!
I recently purchased a 2004 Lincoln Aviator. About a month after I purchased this vehicle it started to develop problems. The rear bearing seal failed and oil is leaking out. The gear shifter on the console is starting to stick and not go into gear. I understand the Aviator is having a lot of problems in these areas. The vehicle only had 79000 miles on it when I purchased it. Ford must have used inferior materials to make the Aviator. Please look into this and if so force Ford to recall the Aviator and replace the inferior parts with parts that are safe and reliable.
The back hatch panel cracked was fixed , the steering not right some times its hard to steer. Main problem is cylinder coils going bad alot. Now #8 coil went bad and has been replaced 2times, and its still in the shop they cant find out why it keeps coming up #8 still misfiring .. They think its the head now. I understand Lincoln has had so many problems with this that they have allowed a 10yr. Extended warranty on all the coils. Is this right ? I want Lincoln to do something. I am so mad right now . I will never buy another Lincoln. Help me.
NHTSA investigations
Spark plug ejection from cylinder head
On September 6, 2005, odi received a petition requesting that the agency investigate allegations of engine spark plug ejection in certain model year 1997 through 2004 Ford vehicles with triton v-8 and v-10 engines.odi received a total of 474 non-duplicative complaints on the subject vehicles where the complainant, or the dealer repairing the vehicle, reported that a spark plug detached from the cylinder and/or…
Engine complaints in other Aviator years
Frequently asked questions
How common are engine problems on the 2004 Lincoln Aviator?
NHTSA has 20 complaints about the engine & cooling of the 2004 Lincoln Aviator, 25% of the model year's 81 complaints. The component named most often is engine (5 mentions).
Is there a recall for 2004 Lincoln Aviator engine problems?
No. NHTSA lists no engine & cooling recall for the 2004 Lincoln Aviator. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Lincoln Aviator engine problems start?
Half of the complaints with a recorded mileage happened before about 74,000 miles, and 11% before 25,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.